Say my hero have an incoming damage of 5 and rolls miserably on his armor, 2d6=4. He successfully redshirts a unit that has 6 armor (standard minifig armor and +2 body armor). So does the minifig redshirting for the hero die? Since the hero would have. Or does the minifig survive? since his armor is enough.

The inspired unit must be on the Hero's team, it must be capable of leaping (e.g., minifigs, robots, or animals, rather than tanks or jet fighters), and it must have a lower CP cost than the Hero (not counting equipment, but counting Crankiness discounts, if any).

When a Hero learns that he's about to take Damage, he has one chance to inspire a nearby RedShirt to take the fall instead. Before the Damage is rolled, the Hero rolls his Skill (plus any Bonus Dice on a Critical Success). If an eligible RedShirt is within this many inches of the Hero, the inspiration succeeds.